Composite circular saw blade

Abstract

A composite circular saw blade. In an exemplary embodiment, a circular saw blade includes a body generally circular in shape including an aperture and an outer periphery. The aperture being generally defined in the center of the body and configured to be at least partially received by a circular saw arbor body. Further, a plurality of teeth are disposed around the outer periphery of the body for providing a cutting edge. The body is formed of a composite material, the composite material including two or more structurally complementary substances in which one of the two or more structurally complementary substances is a matrix material.

1 . A circular saw blade, comprising: 
 a body generally circular in shape including an aperture and an outer periphery, the aperture being generally defined in the center of the body and configured to be at least partially received by a circular saw arbor; and    a plurality of teeth being disposed around the outer periphery of the body for providing a cutting edge,    wherein the body is formed of a composite material, the composite material including two or more structurally complementary substances in which one of the two or more structurally complementary substances is a matrix material.    
   
   
       2 . The circular saw blade as claimed in  claim 1 , wherein the matrix material is a substantially frictionless material.  
   
   
       3 . The circular saw blade as claimed in  claim 1 , wherein the matrix material is a polymeric material.  
   
   
       4 . The circular saw blade as claimed in  claim 1 , wherein the body is formed of polymeric material reinforced with at least one of glass fibers or carbon fibers.  
   
   
       5 . The circular saw blade as claimed in  claim 1 , wherein the body includes heat expansion slots, the heat expansion slots are disposed around the outer periphery of saw blade body for allowing the plurality of teeth to expand during operation.  
   
   
       6 . The circular saw blade as claimed in  claim 1 , further comprising a plurality of tips affixed to the plurality of teeth, the plurality of tips are composed of material selected from the group consisting of carbide, ceramic, steel, and composite.  
   
   
       7 . The circular saw blade as claimed in  claim 1 , wherein the saw blade body includes noise reducing apertures, the noise reducing apertures for attenuation of the sound level generated during blade use.  
   
   
       8 . A saw blade for cutting a fibrous material, comprising: 
 a body generally circular in shape including a centered aperture and a plurality of teeth, the centered aperture configured to be at least partially received by a saw arbor and the plurality of teeth being disposed around an outer periphery of the body; and    a plurality of tips affixed to the plurality of teeth,    wherein the body and the plurality of teeth are composed of a composite material and the plurality of tips affixed to the plurality of teeth provide a cutting edge capable of cutting fibrous material.    
   
   
       9 . The saw blade as claimed in  claim 8 , wherein the composite material for the body and plurality of teeth is selected from the group consisting of a polymeric material reinforced with glass fibers and a polymeric material reinforced with carbon fibers.  
   
   
       10 . The saw blade as claimed in  claim 8 , wherein the body includes heat expansion slots, the heat expansion slots are disposed around the outer periphery of saw blade body for allowing the saw blade to expand during operation.  
   
   
       11 . The saw blade as claimed in  claim 8 , the saw blade body includes noise reducing apertures, the noise reducing apertures for attenuation of the sound level generated during blade use.  
   
   
       12 . The saw blade as claimed in  claim 8 , wherein the plurality of tips are carbide tips.  
   
   
       13 . The saw blade as claimed in  claim 12 , wherein the plurality of carbide tips are attached to the plurality of teeth via an adhesive.  
   
   
       14 . The saw blade as claimed in  claim 12 , wherein the plurality of carbide tips are attached to the plurality of teeth via sonic welding.  
   
   
       15 . A method of manufacturing a saw blade, comprising: 
 forming a mold configured to generate a saw blade including a main body generally circular in shape and a plurality of teeth disposed around an outer periphery of the main body for providing a cutting edge, the mold providing a main body which includes at least a centered aperture configured to be received by a saw arbor;    selecting a composite material for the main body of the saw blade, the composite material including two or more structurally complementary substances in which one of the two or more structurally complementary substances is a polymeric material; and    placing the composite material within the mold to form a composite saw blade in which the plurality of teeth are integral to the main body of the saw blade.    
   
   
       16 . The method of manufacturing as claimed in  claim 15 , further comprising attaching a plurality of carbide tips to the plurality of teeth via sonic welding.  
   
   
       17 . The method of manufacturing as claimed in  claim 15 , further comprising attaching a plurality of carbide tips to the plurality of teeth via an adhesive.  
   
   
       18 . The method of manufacturing as claimed in  claim 15 , wherein the composite material for the main body and plurality of teeth is a polymeric material reinforced with glass fibers.  
   
   
       19 . The method of manufacturing as claimed in  claim 15 , wherein the composite material for the main body and plurality of teeth is a polymeric material reinforced with carbon fibers.  
   
   
       20 . The method of manufacturing as claimed in  claim 15 , wherein the mold provides a main body which includes noise reduction apertures in addition to the centered aperture, the noise reduction apertures allowing the amount of noise generated by the blade during operation to be reduced.